Engine Assembly, Removal

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
a. Discharge fuel system pressure.
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH
5. REMOVE FRONT FENDER SPLASH SHIELD FRONT LH
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN COOLANT
8. DRAIN AUTOMATIC TRANSAXLE FLUID
a. Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain automatic transaxle fluid.
b. Install a new gasket and the drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
9. DRAIN TRANSFER OIL
10. REMOVE BATTERY
11. REMOVE AIR CLEANER ASSEMBLY
12. DISCONNECT RADIATOR HOSE INLET
13. DISCONNECT RADIATOR HOSE OUTLET
14. DISCONNECT OIL COOLER INLET HOSE
15. DISCONNECT OIL COOLER OUTLET HOSE
16. REMOVE ENGINE MOUNTING STAY NO. 2 RH

17. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET
a. Remove the 3 bolts and engine moving control rod.
18. REMOVE ENGINE MOUNTING BRACKET NO. 2 RH
19. REMOVE FAN AND GENERATOR V BELT
20. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

21. DISCONNECT RETURN TUBE SUB-ASSEMBLY
a. Remove the 2 bolts and disconnect the return tube.
22. DISCONNECT UNION TO CHECK VALVE HOSE
23. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
24. DISCONNECT HEATER INLET WATER HOSE
25. DISCONNECT HEATER OUTLET WATER HOSE
26. DISCONNECT FUEL TUBE SUB-ASSEMBLY
a. Disconnect the fuel tube sub-assembly.

27. DISCONNECT ENGINE ROOM MAIN WIRE
a. Disconnect the engine wire from the ECM and J/B.
b. Disconnect the engine wire from the engine room J/B.
(1) Remove the nut fixing the wire harness.
(2) Using a screwdriver, unlock the engine room J/B. Disconnect the engine wire by pulling it upward.
(3) Disconnect the connectors.
(4) Remove the body ground.
28. REMOVE EXHAUST PIPE ASSEMBLY FRONT

29. REMOVE PROPELLER SHAFT (for 4WD)
a. Place the matchmarks on both of the flanges.
b. Remove the 4 nuts, 4 bolts and 4 washers.

c. Insert SST after removing the propeller shaft.
SST 09325-20010
30. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
a. Using a 6 mm socket hexagon wrench, fix the stud bolt.
b. Remove the nut and disconnect the stabilizer link.
31. REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

32. REMOVE FRONT AXLE HUB RH NUT
a. Using SST and a hammer, strike the lock nut covering to remove it.
SST 09930-00010

NOTICE:
^ Set the drive shaft's groove so that it faces up. Then use the SST and a hammer.
^ Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged.
^ Do not sharpen the tip of the SST.

b. Using a 30 mm socket wrench, remove the lock nut.
33. REMOVE FRONT AXLE HUB LH NUT

HINT: Use the same procedures described for the LH side.

34. DISCONNECT SPEED SENSOR FRONT LH
a. Remove the bolt and disconnect the speed sensor from the steering knuckle.

NOTICE: Keep the speed sensor tip and connection free from a foreign matter.

35. DISCONNECT SPEED SENSOR FRONT RH

HINT: Use the same procedures described for the LH side.

36. DISCONNECT TIE ROD ASSEMBLY LH
a. Remove the cotter pin and castle nut.
b. Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011

NOTICE: Be careful not to damage the cover of the ball joint.

37. DISCONNECT TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

38. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
a. Fix the crankshaft and remove the 6 setting bolts.
39. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Use the same procedures described for the LH side.

40. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
a. Fix the crankshaft and remove the 6 setting bolts.

41. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
a. Loosen the sliding yoke bolt.

b. Place matchmarks on the intermediate shaft and control valve shaft.
c. Remove the bolt and the steering intermediate shaft.

d. To prevent the steering wheel from rotating, fix the wheel with the seat belt.

NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged.

42. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH

HINT: Hung up the hoses instead of detaching.

43. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 6 bolts and frame side rail plate RH and LH.

c. Remove the 6 bolts and front suspension member brace rear RH and LH.
d. Carefully remove the engine assembly from the vehicle.

e. Install the 2 engine hangers as shown in the illustration.

Part Nos.:

Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
f. Using a chain block and an engine sling device, hang the engine assembly.

44. REMOVE VANE PUMP ASSEMBLY
a. Disconnect the PS oil pressure switch connector.
b. Remove the 2 bolts and vane pump from the engine.
45. REMOVE STABILIZER BAR FRONT (for 4WD)
46. REMOVE RACK AND PINION POWER STEERING GEAR ASSEMBLY (for 4WD)

47. REMOVE FRONT FRAME ASSEMBLY
a. Remove the nut installing the engine mounting insulator LH.

b. Remove the nut installing the engine mounting insulator RH.

c. Remove the nut installing the engine mounting insulator FR.
48. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

49. REMOVE ENGINE MOUNTING BRACKET RR (for 4WD)
a. Remove the 6 bolts and engine mounting bracket RR.
50. REMOVE TRANSFER ASSEMBLY (for 4WD)
51. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
52. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
53. REMOVE STARTER ASSEMBLY
54. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

55. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
a. Using SST, fix the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

b. Remove the 8 bolts, rear spacer, drive plate and front spacer.
56. INSTALL ENGINE STAND
57. REMOVE ENGINE COVER SUB-ASSEMBLY NO. 1

58. REMOVE INTAKE MANIFOLD
a. Remove the 5 bolts, 2 nuts, intake manifold and gasket.

59. INSPECT INTAKE MANIFOLD
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 2.0 mm (0.079 inch)
If the warpage is greater than the maximum, replace the manifold.
60. REMOVE VENTILATION HOSE NO. 1
61. REMOVE VENTILATION HOSE NO. 2
62. REMOVE ENGINE WIRE
63. REMOVE INTAKE MANIFOLD INSULATOR NO. 1
64. REMOVE GENERATOR ASSEMBLY
65. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
66. REMOVE OIL LEVEL GAGE GUIDE
67. REMOVE MANIFOLD CONVERTER INSULATOR NO. 1

68. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Remove the 3 bolts, 2 nuts, and the No. 1 and No. 2 exhaust manifold stays.

b. Remove the 5 nuts, exhaust manifold converter and gasket.

69. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.70 mm (0.0276 inch)
If the warpage is greater than the maximum, replace the manifold.
70. REMOVE WATER INLET
71. REMOVE THERMOSTAT
72. REMOVE IGNITION COIL ASSEMBLY
73. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

74. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, nut and belt tensioner.
75. REMOVE DRIVE SHAFT BEARING BRACKET (for 2WD)
76. REMOVE ENGINE MOUNTING BRACKET RH
77. REMOVE FUEL DELIVERY PIPE W/INJECTOR
78. REMOVE WATER BY-PASS PIPE NO. 1
79. REMOVE OIL COOLER PIPE (w/Oil Cooler)
80. REMOVE OIL COOLER HOSE (w/Oil Cooler)

81. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Remove the oil pressure switch.

82. REMOVE KNOCK SENSOR
a. Remove the nut and the sensor.
83. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
84. REPLACE PARTIAL ENGINE ASSEMBLY